Low Cost Breakage Detector for Low Voltage Overhead Conductors With Audible Alarm

Have you ever walked past a broken electric line sparking dangerously close to the ground and thought, “Wow… if only something could warn people before someone gets hurt”? That’s exactly what I thought one rainy evening when a low-voltage power line snapped near my street and that moment sparked this project.

For the “Make Some Noise” contest, I decided to build a cost-effective Low Voltage (LV) Breakage Detection System that literally makes noise to save lives. The idea was simple: if a live wire breaks, the system should instantly detect it, cut the power, and sound a loud alarm so people nearby can stay safe.

Once the concept clicked, everything started falling into place. I could use a simple ESP32 as the brain, an MPU6050 sensor to detect vibrations or sudden drops in the line, a relay to isolate the faulty section, and of course, a buzzer that screams for attention. The goal? A setup cheap enough to be installed on every electric pole, yet smart enough to react faster than a human could.

It sounded easy on paper but getting all the sensors, code, and relays to behave together was a whole different story. Between debugging I2C connections, calibrating vibration thresholds, and trying to stop the system from screaming at every gust of wind, I went through my fair share of chaos and caffeine.

By the end of it, I didn’t just have a working prototype I had a small device that could literally prevent electrocution accidents. And even though it’s still a prototype, it’s one loud step closer to making our surroundings safer.

So if you’ve ever wanted to build something that detects danger and makes noise for a purpose, buckle up I’ll walk you through every inch of how I designed, tested, and built this lifesaving little machine: the ShockShield.

Electronics

1. ESP32 microcontroller
2. MPU6050 (3-axis accelerometer + gyroscope)
3. Relay module - 5V
4. Buzzer
5. LEDs –1 Red (Fault) & 1Green (Normal)
6. ZMPT101B Voltage Sensor (for detecting live voltage)
7. Resistors(2)- 220Ω for LEDs
8. Power Supply (5V)
9. Jumper wires and Breadboard / Perfboard

Every successful project starts with a clear goal, and mine began with a simple observation: most electrical accidents in low-voltage areas happen because no one knows when a line has broken until it’s too late.

My idea was to create a cost-effective safety system that could detect when a low-voltage AC overhead conductor breaks or behaves abnormally, and then make noise to warn people in the area before someone gets hurt. The concept was inspired by the fact that even a simple loud buzzer can save a life if triggered at the right time.

My Vision

I wanted a compact, standalone device that could be mounted on any electric pole and act as a watchdog for the power line. It should detect any sudden vibration, breakage, or movement in the wire, and instantly:

1. Isolate the power supply to prevent further damage or electrocution.
2. Trigger a loud alarm so people nearby are alerted.
3. Indicate fault status visually using LEDs for quick inspection.

Key Goals

1. Real-time detection to sense breakage or strong vibration instantly.
2. Automatic response using a relay system to disconnect the live line immediately.
3. Audible and visual alerts using a buzzer and LEDs for both public and maintenance awareness.
4. Simple and low-cost design using easily available components like the ESP32 and MPU6050 sensor.
5. Scalable design that can be implemented across multiple poles in a network.
6. Durable setup that works reliably in outdoor conditions like heat, dust, and rain.

My Approach

I divided the project into three main stages:

1. Detection Module – Using the MPU6050 to identify unusual vibrations that indicate wire breakage.
2. Control and Isolation Unit – Using the ESP32 and relay module to disconnect the power supply automatically.
3. Alert and Indication System – A buzzer and LED setup to notify people and technicians about the fault.

This plan became my roadmap — clear, practical, and focused on saving lives using simple electronic components.

When a low-voltage AC overhead conductor breaks or vibrates abnormally, it becomes a serious safety hazard. The broken line may still carry current, posing a high risk of electrocution to anyone nearby. In many areas, the detection of such faults depends on manual observation or delayed reporting, which means power lines may remain dangerous for several minutes or even hours before the issue is noticed and resolved.

This project addresses that gap by introducing automation. The system continuously monitors the condition of the line using sensors that detect vibrations and motion. When a sudden, abnormal change is detected—indicating a possible breakage or disconnection—it immediately takes action. The relay unit isolates the power supply to prevent further electrical hazards, while the buzzer and LED indicators alert nearby individuals and maintenance teams.

By removing the dependency on human response and introducing real-time detection, this system significantly reduces the chances of accidents and improves overall electrical safety in low-voltage networks.

The design of the system focuses on simplicity, reliability, quick response, and intelligent fault detection using Edge AI. By integrating sensing, control, and alert mechanisms into one compact setup, the system ensures rapid and accurate detection of wire breakage while reducing false alarms.

1. Core Components

1. ESP32 Microcontroller with Edge AI Capability: Serves as the central processor, running lightweight AI models directly on the device. It analyzes sensor data in real time to distinguish between normal and abnormal vibration patterns, minimizing false detections.
2. MPU6050 Sensor: A 3-axis accelerometer and gyroscope module that continuously monitors vibration and motion of the conductor. It captures subtle changes in vibration that indicate potential breakage or instability.
3. Relay Module: Automatically disconnects the power supply when a confirmed fault is detected by the AI logic, preventing electrocution or fire hazards.
4. Buzzer and LED Indicators: Provide instant audible and visual alerts to notify nearby people and maintenance teams.
5. Voltage Sensor: Detects the presence or loss of voltage in the line to verify actual breakage conditions.

2. Working Principle

1. The MPU6050 continuously sends real-time vibration data to the ESP32.
2. The embedded Edge AI algorithm (trained on vibration data) processes these readings locally, identifying patterns that suggest line instability, impact, or disconnection.
3. Normal environmental vibrations such as wind are classified as “safe” by the AI model, while sharp and irregular spikes are flagged as potential faults.
4. When a fault is confirmed, the ESP32 triggers the relay to cut the power supply immediately.
5. The buzzer and red LED are activated to alert nearby people, while system data can optionally be logged or transmitted for maintenance review.

3. Design Objectives

1. Real-time AI-based detection: Use Edge AI for immediate and accurate identification of breakage or dangerous vibrations.
2. Reduced false triggers: Machine-learned vibration classification improves precision compared to simple threshold-based detection.
3. Automatic safety response: Ensure instant relay cutoff and alert activation during fault conditions.
4. Scalability and low cost: Use affordable components and modular design for easy deployment on multiple poles.
5. Environmental durability: Protect all modules to function reliably in outdoor conditions such as heat, dust, and rain.

This enhanced design leverages Edge AI to bring intelligent decision-making directly to the pole, ensuring that every detection is fast, accurate, and dependable—helping to protect both people and electrical infrastructure.

The circuit forms the backbone of the ShockShield system, enabling communication between sensors, control modules, and alert components. Each connection is made to ensure accurate sensing, reliable switching, and quick alerts.

1. MPU6050 Sensor Connection

1. The MPU6050 module communicates with the ESP32 using the I2C protocol.
2. SDA (data line) and SCL (clock line) of the MPU6050 are connected to the respective I2C pins on the ESP32.
3. The sensor continuously sends vibration data to the ESP32 for analysis.
4. Pull-up resistors are used if required for stable I2C communication.

2. Relay Module Connection

1. The relay module is connected to one of the digital GPIO pins of the ESP32.
2. When the ESP32 detects a fault condition, it sends a HIGH signal to the relay.
3. This action disconnects the live wire immediately, preventing power from flowing through a broken line.
4. The relay is powered from the same 5V source used for the ESP32.

3. Buzzer and LED Indicators

1. Separate GPIO pins on the ESP32 are assigned to control the buzzer and LEDs.
2. The buzzer provides an audible alarm to warn nearby people of danger.
3. Red LED indicates a fault condition, while a green LED can be used to show normal operation.
4. Current-limiting resistors are used in series with LEDs for protection.

4. Voltage Sensor Integration

1. A voltage sensor module is connected to the live line to monitor whether current is flowing.
2. The sensor sends feedback to the ESP32, allowing it to verify if power isolation was successful after a breakage.
3. This adds an extra layer of safety by ensuring that the system actually cuts off power.

5. Power Supply Configuration

1. The entire circuit operates on a 5V DC supply.
2. The power is distributed to the ESP32, MPU6050, relay, and buzzer.
3. A regulated power supply or USB input can be used for reliable operation.

6. Assembly Tip

1. Use a perfboard or PCB for stable and permanent wiring.
2. Keep sensor connections short to reduce noise interference.
3. Secure all connections using soldering for better durability in outdoor conditions.

This circuit design ensures smooth communication between components and guarantees that any detected fault results in an immediate and effective safety response.

The ESP32 acts as the intelligent control unit of the system. Writing an efficient program with integrated Edge AI ensures that the device can distinguish between normal environmental vibrations and true fault conditions in real time. The code is written and uploaded using the Arduino IDE, making the system easy to develop, test, and update.

1. Setting Up the Environment

1. The Arduino IDE is used to program the ESP32.
2. Required libraries include Wire.h for I2C communication, MPU6050.h for sensor readings, and TensorFlow Lite Micro or Edge Impulse SDK for lightweight AI model integration.
3. The correct board (ESP32) and COM port are selected before compiling and uploading the code.

2. Sensor Initialization

1. The MPU6050 sensor is initialized using the I2C protocol to read acceleration and gyroscope data.
2. Calibration routines are performed during setup to minimize noise and sensor drift.
3. Baseline vibration values are recorded to establish normal operation patterns.

3. Continuous Data Monitoring

1. The code continuously reads acceleration values across the X, Y, and Z axes.
2. The data is filtered using a moving average or low-pass filter to smooth small fluctuations.
3. These processed readings are fed to the Edge AI model for real-time classification.

4. Edge AI-Based Fault Detection

1. Instead of relying only on fixed thresholds, the AI model analyzes patterns in vibration data.
2. The model is trained to identify abnormal vibrations that occur during breakage or impact.
3. It distinguishes between regular oscillations (like wind) and dangerous spikes that indicate conductor damage.
4. When the AI output classifies an event as a fault, the system proceeds to trigger the safety response.

5. Triggering the Safety Response

1. Upon detection of a confirmed fault:
2. The relay module is deactivated to disconnect power from the broken line.
3. The buzzer turns ON to produce a loud audible alert.
4. The red LED turns ON to indicate a detected fault.
5. The green LED, which indicates normal operation, turns OFF simultaneously.
6. These alerts remain active until the issue is acknowledged and reset.

6. Fault Latching and AI Reset Mechanism

1. When a fault is detected by the AI, the system enters a latched fault state to prevent automatic reactivation.
2. The AI continuously verifies if vibration readings have stabilized post-event.
3. A manual reset button or software reset command is required to return the system to normal operation after human inspection confirms safety.
4. This combination of manual and AI-based control prevents the system from restarting during ongoing hazardous conditions.

7. Serial Monitoring for Testing

1. The Serial Monitor in Arduino IDE is used to display live sensor readings and AI output classifications.
2. This helps visualize how the AI differentiates between normal and abnormal vibrations.
3. Developers can fine-tune model parameters and thresholds during field testing for optimal performance.

8. Final Verification

1. After uploading the program, tests are conducted by creating controlled vibration disturbances and simulated wire breaks.
2. The AI-enhanced ESP32 responds within milliseconds to genuine faults while ignoring regular background motion.
3. This ensures reliable, real-time fault detection suitable for outdoor power line environments.

Through this coding approach, the ShockShield system operates autonomously and intelligently at the edge—providing accurate, fast, and adaptive detection of conductor faults to ensure maximum safety and minimal false alarms.

A reliable power source is essential for continuous operation of the system, especially since it is designed for outdoor deployment. The power integration is carefully planned to ensure uninterrupted functionality, safety, and adaptability for different field conditions.

1. Primary Power Source

1. The system is powered by a 5V DC adapter, which provides a stable and regulated voltage for the ESP32, MPU6050 sensor, relay module, buzzer, and LEDs.
2. The adapter is connected through a DC jack or terminal block for secure wiring.
3. This power setup is ideal for testing and indoor demonstrations.

2. Outdoor Power Options

1. For outdoor installations, the system can be operated in two alternative ways:
2. Solar-Powered Battery: A compact solar panel with a rechargeable lithium-ion battery can be used to ensure continuous power supply even during grid outages. The panel charges the battery during the day, and a small charge controller regulates the voltage to maintain stable 5V output.
3. Grid Tap Method: The system can draw low-voltage power directly from the existing distribution line through a step-down converter or transformer. This method ensures that the system remains operational as long as the grid is active.

3. Voltage Regulation and Distribution

1. A voltage regulator or DC-DC converter maintains a constant 5V output to protect the ESP32 and sensors from voltage fluctuations.
2. The power is distributed across all components through a perfboard or PCB layout with proper trace routing for current stability.
3. Additional decoupling capacitors are placed near the ESP32 and MPU6050 to filter noise and improve sensor accuracy.

4. Efficiency and Sustainability

1. The entire setup consumes minimal power (typically under 500 mA), making it suitable for solar or battery-based operation.
2. This low-power design ensures that the ShockShield system can function continuously for long durations without frequent charging or maintenance.

Through this power supply integration, the system becomes adaptable for both testing environments and real-world outdoor installations—ensuring reliable, continuous protection against low-voltage line breakages.

The alert mechanism of the system is designed to provide both visual and auditory signals immediately after a conductor breakage is detected. This ensures that anyone nearby is quickly warned about the potential electrical hazard, while maintenance personnel can easily identify the fault location.

1. Normal Operation

1. During normal conditions, the green LED remains ON.
2. This indicates that the power supply is active and the system is functioning properly.
3. The buzzer and red LED remain OFF to signal safe operation.

2. Fault Detection Trigger

1. When the system (via the MPU6050 sensor and Edge AI algorithm) detects an abnormal vibration or line breakage, it instantly switches to fault mode.
2. The ESP32 processes the signal and activates the alert sequence without delay.

3. Automatic Safety Response

1. Relay OFF: The relay is deactivated, cutting off the live power supply to the broken conductor. This prevents electrical hazards such as electrocution or fire.
2. Buzzer ON: A high-decibel buzzer immediately turns ON to produce a continuous warning sound, alerting people in the surrounding area to stay away from the faulty line.
3. Red LED ON: A bright red LED turns ON to provide a visible fault indication even in daylight or from a distance.

4. Continuous Alert Mode

1. The buzzer and red LED remain active until the system is manually reset after inspection.
2. This ensures that the alert remains noticeable until the fault is acknowledged and corrected.

5. Reset and Return to Normal

1. Once the line is inspected and repaired, the manual reset switch is pressed to restore normal operation.
2. The red LED and buzzer turn OFF, and the green LED lights up again, indicating that the system is back to its monitoring mode.

This combined visual and auditory alert mechanism ensures immediate awareness of electrical faults, helping prevent accidents and enabling quick maintenance response.

To ensure the reliability and robustness of the LV breakage detection system, several tests were conducted under different conditions:

1. Vibration Test – Minor vibrations and small shakes were applied to the setup. The system remained stable, and no false alerts were triggered, confirming vibration resistance.
2. Break Simulation Test – A sharp jerk was used to simulate an actual wire breakage. The system immediately detected the break and triggered the alert mechanism without delay.
3. Power Isolation Test – The relay was manually disconnected to check power cut functionality. The power supply to the broken line was successfully isolated, preventing any risk of electrical hazards.
4. Distance Test – The buzzer alert was clearly audible up to a distance of 20 meters, ensuring effective warning coverage even in noisy environments.

These tests verified that the system performs accurately, providing quick detection, stable operation, and dependable safety alerts.

1. Detection Time: The system detected line breakage in less than 1 second, ensuring rapid response and safety.
2. False Alarm Rate: After proper calibration, the false alarm rate was very low, indicating high accuracy in detection.
3. Power Consumption: The system operated efficiently with a power usage of less than 5W, suitable for both grid and solar power supply.
4. Environmental Performance: The system worked reliably under varying wind speeds and temperature conditions, proving its robustness for outdoor applications.

1. The system offers an innovative and reliable solution for detecting LV line breakage.
2. It provides an affordable and practical approach to improving electrical safety in both rural and urban areas.
3. By integrating vibration sensing, automated power isolation, and audible-visual alerts, the system minimizes the risk of electrocution accidents.
4. Its quick response time and low power consumption make it suitable for continuous field operation.
5. Overall, ShockShield enhances public safety and demonstrates the effectiveness of smart monitoring in electrical distribution systems.